Decorative articles and method of making same

ABSTRACT

A light-reflective decorative article is made by placing a foil sheet over a plurality of discrete, shaped particles of synthetic plastic material, thereupon fixing portions of the foil sheet on upper surfaces of the particles, and thereupon peeling the foil sheet off the particles but leaving behind the fixed foil sheet portions.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. Ser. No. 08/268,965, filed Jul.7, 1994, now U.S. Pat. No. 5,597,434.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention generally relates to decorative articles having bead-likeparticles thereon and, more particularly, to making such articles withlight-reflective characteristics.

2. Description of the Related Art

It is known from U.S. Pat. No. 3,377,184 to apply a tacky adhesive,preferably a polyvinylchloride plastisol, to a base fabric material in adesired pattern, and thereupon to apply or flock a plurality ofbead-like pieces or particles of synthetic plastic material onto thetacky adhesive. The excess particles are then removed. The adhesive iscured by being heated. The plastic particles are thus fixedly set to thefabric material. The plastic particles actually melt slightly during thecuring and fuse with the adhesive. The adhesive may be applied thickeror thinner depending on its proposed use; see, for example, U.S. Pat.No. 3,582,440.

It is also known from U.S. Pat. No. 3,806,397 to apply a multitude oflight-reflective flakes (also known as "glitter") onto such an adhesivewhich has been applied to a release paper material. Each flake has analuminum core which is coated over its entire periphery with a thinlayer of a transparent polyvinylchloride. To cure the adhesive, heat isapplied thereto and to the flakes on the adhesive. During this heatingstep, the transparent layer of polyvinylchloride that coats the flakesmelts slightly and fuses with the adhesive. The flakes being essentiallytwo-dimensional, planar and thin, e.g., on the order of 4 mils, lay flatagainst the release material.

Although generally satisfactory for their intended purpose, the knownprocesses of making a light-reflective, decorative article requires agreat quantity of coated light-reflective flakes to be manufactured andused. Also, since the transparent coatings melt to different extentsduring curing of the adhesive, the light-reflective characteristics, aswell as the adhesion force, of the flakes vary. It is difficult topredict and/or control such variations, thereby leading to non-uniformproduction of the decorative articles.

SUMMARY OF THE INVENTION

Objects of the Invention

It is a general object of this invention to provide a novel method ofmaking a light-reflective decorative article.

Another object of this invention is to decorate an article, such as afabric, with light-reflective particles while avoiding theaforementioned difficulties and drawbacks of the prior art.

Still another object of this invention is to make a relativelylightweight material having a light-reflective characteristic that canreadily be used in wearing apparel.

Yet another object of this invention is to make a light-reflectivedecorative article that can be folded, cut, rolled, sewn, draped, washedand cleaned with ease, without the light-reflective particles fallingoff the article during such procedures.

An additional object of this invention is to provide a light-reflectivefabric from which the light-reflective particles will not flake off,especially when worn.

Another object of this invention is to provide a decorative articlewhich simulates a stone-like, nail-head, studded, metal ornamented,bugle-beaded, raised appearance.

Features of the Invention

In keeping with these objects and others which will become apparenthereinafter, one feature of this invention resides, briefly stated, in amethod of making a light-reflective decorative article, which comprisesthe steps of applying an adhesive on a base layer, adhering a pluralityof discrete, shaped particles of synthetic plastic material to the baselayer by contacting lower surfaces of the particles on the adhesive, andsecuring a light-reflective coating solely on upper surfaces of theparticles above the base layer and out of contact with the adhesive.

The securing step is advantageously performed by placing a foil sheet,preferably a laminated foil sheet, over the particles, fixing portionsof the foil sheet on the upper surfaces of the particles, and peelingthe foil sheet off the particles but leaving behind the fixed foil sheetportions. The fixing step is performed by heating and pressing the foilsheet against the upper surfaces of the particles.

Thus, in accordance with this invention, it is no longer necessary touse a great quantity of light-reflective flakes having an aluminum corewith a surrounding transparent coating. Instead, fewer and essentiallythree-dimensional plastic particles are used. There are no transparentcoatings and, hence, no variation in the melting of such coatings, novariation in the light-reflective characteristics of the particles, andno variation in the adhesion force of the particles. The production ofsuch decorative articles is more uniform than heretofore. The decorativearticles have a richer, raised appearance. There are fewer particlesand, hence, a decreased tendency for the particles to fall off duringuse or cleaning.

Still another feature of this invention resides in making an irremovableapplique on a decorative article, comprising the steps of applying anadhesive on a release sheet, adhering a plurality of the plasticparticles to the release sheet, removing the release sheet to form theapplique, and permanently fixing the applique to a base layer.

An adhesive may be applied between the applique and the base layer. Alight-reflective coating may be secured solely on upper surfaces of theparticles above the release sheet and out of contact with the adhesive.As before, the securing step is performed by placing a foil sheet overthe particles, fixing portions of the foil sheet on the upper surfacesof the particles, and peeling the foil sheet off the particles butleaving behind the fixed foil sheet portions. Advantageously, the fixingstep is performed by heating and pressing the foil sheet against theupper surfaces of the particles.

The novel features which are considered as characteristic of theinvention are set forth in particular in the appended claims. Theinvention itself, however, both as to its construction and its method ofoperation, together with additional objects and advantages thereof, willbe best understood from the following description of specificembodiments when read in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an enlarged sectional view of a light-reflective decorativearticle in accordance with this invention at one stage of itsmanufacture;

FIG. 2 is a perspective view of the article of FIG. 1 after manufacture;

FIGS. 3A, 3B and 3C are perspective views of differently shapedparticles for use in the manufacture of the article of FIG. 2;

FIG. 4 is an enlarged sectional view taken on line 4--4 of FIG. 2showing the peeling of a foil sheet from the particles at a stage ofmanufacture subsequent to that shown in FIG. 1;

FIG. 5 is a perspective view of another embodiment of a decorativearticle in accordance with this invention at one stage of itsmanufacture;

FIG. 6 is an enlarged sectional view of the article of FIG. 5 during asubsequent stage of its manufacture; and

FIG. 7 is an enlarged sectional view of the article of FIG. 5 aftermanufacture.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, reference numeral 10 in FIG. 2 shows alight-reflective decorative article manufactured in accordance with thisinvention. As described below, the article 10 is comprised of aplurality of discrete, shaped particles or beads 12 of synthetic plasticmaterial. As shown, the particles are arranged in the shape of afive-pointed star. However, it will be readily understood by thoseskilled in this art that the arrangement of the particles may take anyone of an infinite number of shapes or forms, and all such possibilitiesare intended to be covered by this invention.

The article 10 comprises a base layer 14. Advantageously, the base layer14 is a fabric, either woven or non-woven, stretchable ornon-stretchable, and preferably made from natural fibers, syntheticfibers, or combinations thereof. Preferably, the fabric is readilyrolled, cut or sewn, so that it can be used for such applications asclothing, handbags, shoes, scarves, etc.

A layer of an adhesive 16 is applied over the base layer 14 in anydesired pattern or design. Preferably, the adhesive is a curableplastisol which is applied in a liquid state to the base layer 14,either by hand or through a sieve, stencil, screen or analogouspattern-forming device to obtain the desired pattern. The wet adhesivepenetrates slightly among the interstices of the base layer 14.

Basically, the plastisols are composed of vinyl chloride resin particlesdispersed in a plasticizer to which may be added stabilizers, pigments,gelling agents, mineral spirits (for thinning) and similar modifyingadditives. The formulation of plastisols usable with the presentinvention is quite wide. For example, based upon 100 parts by weight ofvinyl chloride resin, the amount of plasticizer may vary from 50 partsto 200 parts and the amount of pigment, stabilizers and/or othermodifying components may vary between 0 and 10 parts.

Typical examples of plastisols which may be used with the presentinvention are as follows:

    ______________________________________                         Pounds    ______________________________________    (1)    Polyvinylchloride resin (QYNV)                         100    Diisooctylphthalate  80    Dibutyl tin maleate  1    (2)    Polyvinylchloride resin (Geon 121)                         100    Dioctylphthalate     80    Barium-cadmium laurate                         1    (3)    Polyvinylchloride resin (Exon 654)                         100    Tri cresyl phosphate 80    Tri basic lead stearate                         2    ______________________________________

Plastisols made according to the above formulations have thecharacteristics of pliability, flexibility and softness rather than thestiffness and hardness of other types of adhesives. They may be readilycut or sewn and then can withstand repeated washing or dry cleaning andhave good, long-lasting wearing characteristics. If desired, theseplastisols may contain pigmentation and may be thinned by mineralspirits. In this manner, the polyvinylchloride may be thinned to be freeflowing for a flat appearance, or thickened so as to be viscous to givea high raised appearance where desired.

In the preferred embodiment, the plastisol is applied by being pressedthrough openings in a silk screen. The plastisol flows freely throughthe screen openings and will not clog them, thereby assuring that thescreen can be re-used. The openings may have extremely fine detail and,hence, the adhesive pattern can be likewise very detailed.

Next, the plastic particles 12 are applied to the wet adhesive beforethe adhesive has dried or is cured. The particles 12 are preferably madefrom lengths of extruded plastic which are cut into the desired shapeand size. The plastic particles may be solid, hollow, flat, or of anyother desired configuration. See, for example, FIGS. 3A, 3B and 3C whichshow representative cylindrical, spherical and football-shaped particles12', 12" and 12'", respectively. The plastic particles arethree-dimensional and, in a preferred embodiment, each measures about 50mils along each dimension.

In the preferred embodiment, the particles are made of a plastic fromthe polyvinyl group, preferably polyvinylchloride. Such particles arereadily held by the plastisol adhesive. Additional suitable plastics maybe selected for the particles from those plastic compounds havingpolymers obtained from polymerization of unsaturated compounds. Theplastic particles are relatively soft so that they can be cut or sewnthrough. They are also durable enough to maintain their shape throughouttheir life and can be dry cleaned or washed at normal temperatures. Theplastic particles are relatively light so that a large number may beplaced on a piece of the base layer 14 without unduly weighing it down.Any combination of colors, shapes and/or sizes of plastic particles maybe utilized on a single piece of base layer as desired. The plasticparticles cover up the plastisol to a large extent so that the plastisoldoes not show through. All of these features make the finisheddecorative article suitable for a wide variety of uses.

The particles are flocked onto the adhesive-coated pattern on the baselayer by hand or by using a suitable sieve. The plastic particles stickto the wet, tacky, adhesive-coated portions, and a pattern of plasticparticles corresponding to the pattern of the adhesive is laid down onthe base layer.

After the plastic particles are applied to the base layer, the excessparticles which did not initially adhere to the base layer are removed,for example, by shaking the base layer or by using air or gas to blowoff the excess particles. Preferably, a vacuum cleaner or analogoussuction device picks up the excess particles. As shown in FIG. 1, onlythe excess particles are removed, and the remaining particles have lowerportions 12A which are in contact with the plastisol 16 and which areadhered to the base layer 14.

In order to firmly fix the portions 12A of the plastic particles 12 tothe base layer, the plastisol is heated to its curing point, i.e., thetemperature at which the polyvinylchloride particles in the plastisolsolidify. This is accomplished by placing the base layer on a heatedplate, or by placing it in an oven, or by using infrared heating lamps,or by using any other suitable heating means. All of the plastisolsdescribed above have a heat curing temperature in the range of between300° F. to about 400° F., and all will adhere firmly to a fabric orother porous material. It is preferred that a plastisol which cures at300° F. and above be used so that the finished garment will withstandthe highest temperatures usually encountered in a commercial drycleaning process.

In accordance with this invention, a light-reflective coating is securedsolely over and on upper surfaces 12B of the particles. A foil sheet 18is placed over and on the upper surfaces 12B. The foil sheet 18 ispreferably a laminated sheet and has an outer layer 20 constituted of alight-reflective material, e.g., a metal; a carrier layer 22 constitutedof a plastic material, e.g., polyester mylar; and an inner layer 24constituted of a heat-sensitive adhesive curable at temperatures atleast equal to 300° F. A foil sheet suitable for this purpose ismanufactured by Crown Roll Leaf, Inc., of Paterson, N.J. and marketed asModel No. "MK44." The inner adhesive layer 24 is preferably applied tothe sheet at the time of the sheet manufacture, rather than beingapplied during the making of the article.

As shown in FIG. 1, the foil sheet 18 is pressed by a drive, e.g., apiston 30, against the upper surfaces 12B of the particles. At the sametime, the foil sheet 18 is heated by a heater, e.g., a resistive element32 mounted within the piston 30. The heater is operative to generatetemperatures on the order of 300° F. to cure the adhesive layer 24. Thedrive is pressed against the particles with a force on the order of 150psi for about 5 seconds.

Those portions of the foil sheet which are pressed against the uppersurfaces 12B are fixed thereto. Thereupon, the foil sheet 18, as shownin FIG. 4, is pulled off the particles. Those fixed portions of thesheet remain on the upper surfaces 12B. All the other portions of thesheet, labelled by reference numeral 40 in FIG. 4, are removed duringthe peeling step. The sheet 18 is sufficiently thin, on the order of afew mils, and flexible to be pressed against particles 14 of differentsizes and elevations relative to the base layer. The finished article isthus provided with a light-reflective coating which is provided only onthe upper surfaces 12B and which does not, as taught in the prior art,completely encircle the particles. Also, the finished article has araised appearance which simulates the appearance of more expensive,metal-ornamented fabrics.

Turning now to FIGS. 5 through 7, the base layer 14 need not be a fabricmaterial as described above, but could instead be a release layer 50such as paper, either uncoated or coated with a release coating. Asbefore, a plastisol 52 is applied in a pattern on the release layer 50,and a plurality of discrete particles 54 of synthetic plastic materialand of different sizes and shapes is flocked on the plastisol 52. Aheater 56 (see FIG. 5) cures the plastisol 52 and fixes the lowersurfaces of the particles 54 securely in place in the plastisol 52.

Thereupon, as shown in FIG. 6, the release layer 50 can be removed bypeeling from the underside of the plastisol 52, thereby forming anapplique 60. The applique can be used as is, or, a foil sheet 68,analogous to the aforementioned foil sheet 18, is applied over andsecured to the particles 54 in a manner completely analogous to thatdescribed above. Peeling the foil sheet 68 from the particles 54 willresult in a light-reflective coating on the upper surfaces of theparticles. The light-reflective applique can be used as a decoration byitself, e.g., as a Christmas ornament or the like.

Alternatively, the applique 60, with or without the application of thefoil sheet 68, may be applied either directly to a base layer 62, e.g.,a fabric material, or the plastisol 52 is applied between the applique60 and the base layer 62. In either event, a heater 64 is used topermanently affix the applique 60 to the base layer 62. The resultingdecorative article is shown in FIG. 7.

It will be understood that each of the elements described above, or twoor more together, also may find a useful application in other types ofconstructions differing from the types described above.

While the invention has been illustrated and described as embodied indecorative articles and a method of making same, it is not intended tobe limited to the details shown, since various modifications andstructural changes may be made without departing in any way from thespirit of the present invention.

Without further analysis, the foregoing will so fully reveal the gist ofthe present invention that others can, by applying current knowledge,readily adapt it for various applications without omitting featuresthat, from the standpoint of prior art, fairly constitute essentialcharacteristics of the generic or specific aspects of this inventionand, therefore, such adaptations should and are intended to becomprehended within the meaning and range of equivalents of thefollowing claims.

What is claimed as new and desired to be protected by Letters Patent isset forth in the appended claims:

I claim:
 1. A decorative, flexible article having a raised,light-reflective pattern thereon, comprising:a) a flexible basematerial; b) a curable plastisol adhesive applied in the pattern on thebase material; c) a plurality of discrete, shaped particles of syntheticplastic material each having a longitudinal dimension on the order of 50mils, each particle having lower surfaces in direct contact with theplastisol adhesive prior to curing, and upper surfaces facing away fromthe plastisol adhesive; and d) laminated foil sheet portions on theupper surfaces of the particles, each laminated sheet portion having aheat-sensitive, settable adhesive layer in direct contact with the uppersurfaces of the particles, a carrier layer, and a light-reflecting layerfacing away from the particles, said carrier layer being located betweenthe adhesive layer and the light-reflecting layer.
 2. The articleaccording to claim 1, wherein the flexible base material is a fabric. 3.The article according to claim 1, wherein the adhesive is apolyvinylchloride plastisol.
 4. The article according to claim 1,wherein the plastic material of the particles is polyvinylchloride. 5.The article according to claim 1, wherein the particles are of differentshapes.
 6. The article according to claim 5, wherein the particles areconstituted of extruded pieces of the plastic material.
 7. The articleaccording to claim 1, wherein the light-reflecting layer is constitutedof a metallic material.
 8. The article according to claim 1, wherein thecarrier layer is constituted of a plastic material.
 9. The articleaccording to claim 8, wherein the carrier layer is a polyester mylar.10. The article according to claim 1, wherein the heat-sensitive,settable adhesive layer cures at temperatures at least equal to 300° F.11. The article according to claim 1, wherein the flexible base materialis a release layer.